Two-wheeled vehicle

ABSTRACT

A two-wheeled vehicle includes a frame having a front frame portion, a mid-frame portion, and a rear frame portion. The mid-frame portion is coupled to the rear frame portion and the front frame portion. The vehicle further includes a plurality of ground-engaging members for supporting the frame. The front frame portion is removably coupled to the mid-frame portion with a plurality of frame members extending between the front frame portion and the mid-frame portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional PatentApplication Ser. No. 61/799,880, filed on Mar. 15, 2013, and entitled“TWO-WHEELED VEHICLE,” the complete disclosure of which is expresslyincorporated by reference herein.

BACKGROUND OF THE DISCLOSURE

The present disclosure relates to two-wheeled vehicles and, moreparticularly, to motorcycles having a modular frame.

Conventional two-wheeled vehicles include a frame for supporting anoperator. The frame may also support a passenger rearward of the driver.An engine is typically positioned below the driver and is coupled to theframe. The front of the vehicle may include a panel or cover positionedforward of the driver for supporting additional components of thevehicle, for example a light. The rear of the vehicle may include acargo area, for example saddle bags extending laterally outward from theframe.

SUMMARY OF THE DISCLOSURE

In an exemplary embodiment of the present invention, a two-wheeledvehicle comprises a frame assembly including a front frame portionincluding a head portion, a plurality of generally vertically-extendingframe tubes, and a plurality of generally longitudinally-extending frametubes. The frame assembly further includes a mid-frame portion removablycoupled to the front frame portion and a rear frame portion removablycoupled to the mid-frame portion. The two-wheeled vehicle furthercomprises a plurality of ground-engaging members for supporting theframe assembly and an air intake assembly coupled to the head portionand the longitudinally-extending frame tubes. Thelongitudinally-extending frame tubes are angled outwardly to increase adistance therebetween. The air intake assembly is positioned between thelongitudinally-extending frame tubes and includes channel membersconfigured to receive the longitudinally-extending frame tubes.

In a further exemplary embodiment of the present invention, atwo-wheeled vehicle comprises a frame assembly including a front frameportion including a head portion, a plurality of generallyvertically-extending frame tubes, and a plurality of generallylongitudinally-extending frame tubes. The frame assembly also includes amid-frame portion removably coupled to the front frame portion and arear frame portion removably coupled to the mid-frame portion. Thetwo-wheeled vehicle further comprises a plurality of ground-engagingmembers for supporting the frame assembly and an air intake assemblycoupled to the head portion. The air intake assembly includes a filterand a first portion of air received into the air intake assembly isdirected from the filter of the air intake assembly into the headportion of the front frame portion. Additionally, the two-wheeledvehicle comprises a throttle body coupled to the air intake assembly anda second portion of the air received into the air intake assembly flowdirectly from the filter into the throttle body.

In another exemplary embodiment of the present invention, a two-wheeledvehicle comprises a frame assembly including a front frame portionincluding a head portion, a plurality of generally vertically-extendingframe tubes, and a plurality of generally longitudinally-extending frametubes. The frame assembly also includes a mid-frame portion removablycoupled to the front frame portion and a rear frame portion removablycoupled to the mid-frame portion. The two-wheeled vehicle furthercomprises a plurality of ground-engaging members for supporting theframe assembly and a cooling assembly positioned below the head portionand intermediate the vertically-extending frame tubes. A lower end ofthe cooling assembly is coupled to a lower end of thevertically-extending frame tubes, and an upper end of the coolingassembly is frictionally retained at an upper end of each of thevertically-extending frame tubes.

In a further exemplary embodiment of the present invention, atwo-wheeled vehicle comprises a frame assembly including a front frameportion including a head portion, a plurality of generallyvertically-extending frame tubes, and a plurality of generallylongitudinally-extending frame tubes. The frame assembly also includes amid-frame portion removably coupled to the front frame portion and arear frame portion removably coupled to the mid-frame portion. Thetwo-wheeled vehicle further comprises a front ground-engaging member forsupporting the frame assembly and a rear ground-engaging member forsupporting the frame assembly. Additionally, the two-wheeled vehiclecomprises a rear suspension assembly operably coupled to the rearground-engaging member. The rear suspension assembly includes a firstswing arm coupled to the mid-frame portion, a second swing arm coupledto the mid-frame portion, and a pivot axle extending between the firstand second swing arms. Rotation of the pivot axle is configured toadjust the position of the mid-frame portion relative to the first andsecond swing arms.

In another exemplary embodiment of the present invention, a two-wheeledvehicle comprises a frame assembly including a front frame portionincluding a head portion, a plurality of generally vertically-extendingframe tubes, a plurality of generally longitudinally-extending frametubes, and a plurality of plate members coupled to thelongitudinally-extending frame tubes and extending downwardly therefrom.The frame assembly also includes a mid-frame portion removably coupledto the front frame portion and a rear frame portion removably coupled tothe mid-frame portion. The two-wheeled vehicle further comprises aplurality of ground-engaging members for supporting the frame assemblyand a fuel tank coupled to the plate members. An upper end of the platemembers is permanently coupled to the longitudinally-extending frametubes and a lower end of the plate members is coupled to the headportion.

In a further exemplary embodiment of the present invention, a method forassembling a two-wheeled vehicle comprises the steps of providing amodular front frame portion, providing a modular mid-frame portion, andcoupling the mid-frame portion to the front frame portion. Additionally,the method comprises the steps of providing a modular rear frame portionand coupling the rear frame portion to the mid-frame portion. The methodalso comprises the steps of providing a plurality of vehicle componentsselected from the group consisting of handlebars, wheels, an exhaustassembly, a seat, a fuel tank, a front fender, a rear fender, and aswing arm assembly, and coupling the vehicle components to at least oneof the front frame portion, the mid-frame portion, and the rear frameportion. Each of the vehicle components has a plurality of sizes,shapes, and styles, and the modular frame portions are configured toaccommodate the various sizes, shapes, and styles of each of the vehiclecomponents.

The above mentioned and other features of the invention, and the mannerof attaining them, will become more apparent and the invention itselfwill be better understood by reference to the following description ofembodiments of the invention taken in conjunction with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a left front perspective view of a frame assembly of atwo-wheeled vehicle of the present disclosure;

FIG. 2 is a right rear perspective view of the frame assembly of FIG. 1;

FIG. 3 is an exploded view of the frame assembly of FIG. 1;

FIG. 4 is a cross-sectional view of a portion of the frame assembly ofFIG. 1, taken along line 4-4 of FIG. 1;

FIG. 5 is a right rear perspective view of a front frame portion of theframe assembly of FIG. 1 in a partially exploded manner;

FIG. 6 is an exploded view of a powertrain assembly of the two-wheeledvehicle and the front frame portion of FIG. 5;

FIG. 7 is a left rear perspective view of a side stand of thetwo-wheeled vehicle of FIG. 1;

FIG. 8 is a right rear perspective view a portion of the powertrainassembly of FIG. 6;

FIG. 9 is an exploded view of the portion of the powertrain assembly ofFIG. 8;

FIG. 10 is a left front perspective view of a portion of an electricalsystem and a coolant bottle of the two-wheeled vehicle of FIG. 1;

FIG. 11 is an exploded view of the portion of the electrical system andthe coolant bottle of FIG. 10;

FIG. 12 is a right rear perspective view of a radiator assembly coupledto a portion of the frame assembly of FIG. 1;

FIG. 13 is an exploded view of a lower portion of the radiator assemblyand frame assembly of FIG. 12;

FIG. 14 is an exploded view of an upper portion of the radiator assemblyand frame assembly of FIG. 12;

FIG. 15 is a rear cross-sectional view of the upper portion of theradiator assembly of FIG. 12, taken along line 15-15 of FIG. 12;

FIG. 16 is a left rear perspective view of an air intake assemblycoupled to front frame of FIG. 1;

FIG. 17 is an exploded view of the air intake assembly and the frontframe of FIG. 16;

FIG. 18 is an exploded view of an air box of the air intake assembly ofFIG. 16;

FIG. 19 is a side cross-sectional view of the air intake assembly ofFIG. 16, taken along line 19-19 of FIG. 16;

FIG. 20 is a right rear perspective view of a fuel tank of thetwo-wheeled vehicle of FIG. 1;

FIG. 21 is an exploded view of the fuel tank of FIG. 20 and a portion ofthe frame assembly;

FIG. 22 is a top view of the fuel tank of FIG. 20 with a partial planview of a fuel pump assembly within the fuel tank;

FIG. 23 is a side view of the fuel tank of FIG. 20 with a partial planview of the fuel pump of FIG. 22;

FIG. 24 is an exploded view of a seat and the frame assembly;

FIG. 25 is a side view of a rear frame of a rear suspension assembly ofthe two-wheeled vehicle of FIG. 1;

FIG. 26A is an exploded view of a rear portion of the two-wheeledvehicle of FIG. 1;

FIG. 26B is a side view of an alternative embodiment of the rearsuspension assembly of FIG. 26A;

FIG. 27 is a left front perspective view of a rear fender of the rearportion of the two-wheeled vehicle;

FIG. 28 is a left rear perspective view of the rear fender of FIG. 27coupled to a rear light assembly;

FIG. 29 is an exploded view of a front portion of the rear suspensionassembly of FIG. 25;

FIG. 30 a right front perspective view of a pivot axle of the rearsuspension assembly of FIG. 27;

FIG. 31 is a front cross-sectional view of the pivot axle of the rearsuspension assembly of FIG. 25, taken along line 31-31 of FIG. 25;

FIG. 32 is an exploded view of a foot peg assembly of the two-wheeledvehicle of FIG. 1;

FIG. 33 is a rear left perspective view of a drive wheel and beltcoupled to a rear wheel axle of the two-wheeled vehicle of FIG. 1;

FIG. 34 is an exploded view of the rear axle of FIG. 33;

FIG. 35 is a left front perspective view of a front portion of thetwo-wheeled vehicle of FIG. 1;

FIG. 36 is a right rear exploded view of the front portion of thetwo-wheeled vehicle of FIG. 35; and

FIG. 37 is a right rear perspective view of an alternative embodiment ofthe front portion of the two-wheeled vehicle of FIG. 36.

Corresponding reference characters indicate corresponding partsthroughout the several views. Unless stated otherwise the drawings areproportional.

DETAILED DESCRIPTION OF THE DRAWINGS

The embodiments disclosed below are not intended to be exhaustive or tolimit the invention to the precise forms disclosed in the followingdetailed description. Rather, the embodiments are chosen and describedso that others skilled in the art may utilize their teachings. While thepresent invention primarily involves a cruise motorcycle, it should beunderstood, that the invention may have application to other types ofvehicles such as all-terrain vehicles, motorcycles, watercraft, utilityvehicles, scooters, golf carts, and mopeds.

An illustrative embodiment of a two-wheeled vehicle 2 is shown. Vehicle2 is a mid-size motorcycle having a wheel base of approximately 58-65inches and, more particularly, is approximately 61.5 inches. Vehicle 2includes a front end and a rear end supported by a plurality ofground-engaging members, for example a front wheel and a rear wheel. Thefront and rear wheels are generally aligned along a centerline ofvehicle 2. While vehicle 2 is a two-wheeled vehicle, various embodimentsof the present disclosure may include three, four, five, or six-wheeledvehicles. A front fender may be partially positioned around the frontwheel and may include a light or reflector. Similarly, a rear fender 400may be partially positioned around the rear wheel. Additionally, a brakeassembly 12 is operably coupled to the front and rear wheels. Brakeassembly 12 includes brake discs and may further include an anti-lockingbraking module 160 (FIGS. 17 and 18).

Vehicle 2 also includes a front suspension assembly, a steering assembly24, operator controls 26, and other systems. Steering assembly 24includes handlebars 30 which may be moved by an operator to rotate thefront wheel. Steering assembly 24 is coupled to vehicle 2 through atriple clamp assembly 32.

Vehicle 2 also includes a frame assembly 50 for supporting a powertrainassembly 130, a cooling assembly 240, a fuel tank 300, a rear suspensionassembly 380, and an operator seat 28. Referring now to FIGS. 1-4, frameassembly 50 is a modular assembly that includes a front frame 52, amid-frame 53, and a rear frame 54. Because frame assembly 50 is modular,various components of vehicle 2, such as an air intake assembly 300, anexhaust assembly 360, cooling assembly 240, operator controls 26,steering assembly 24, seat 28, front suspension assembly 20, and rearsuspension assembly 380, may be replaced with alternative embodimentswithout reconfiguring frame assembly 50 to support these alternativeembodiments. Additionally, front frame 52, mid-frame 53, and rear frame54 are generally coupled together and coupled with other components ofvehicle 2 without requiring heat treatments or permanent couplers (i.e.,welds). As such, various components of vehicle 2 may be replaced withalternative components without requiring a new frame assembly.

Front frame 52 is positioned forward of mid-frame 53 and rear frame 54and includes down tubes or front arm members 56 and frame rails 58.Mid-frame 53 includes side members 60 and is coupled to both front frame52 and rear frame 54. As detailed further herein, mid-frame 53 is boltedto front frame 52 and rear frame 54, which eliminates the need for heattreating and permanently coupling together the portions of frameassembly 50.

Front arm members 56 of front frame 52 extend downwardly from a headportion 62. Additionally, front arm members 56 may be angled rearwardlyrelative to head portion 62. The lower ends of front arm members 56include a plurality of apertures 68, 70 for coupling with powertrainassembly 130. Front arm members 56 cooperate with head portion 62 toform a pocket 66, as detailed further herein.

Head portion 62 includes a head tube 64 for coupling with steeringassembly 24. Head portion 62 also includes a plurality of apertures 72(FIG. 3) for coupling with frame rails 58, as detailed further herein.Apertures 72 are located within recesses 71 of head portion 62. Frontarm members 56, head portion 62, and head tube 64 may be a singleuniform component formed through casting methods. Alternatively, eachfront arm member 56 may be integrally formed with approximately half ofhead 62 and approximately half of head tube 64. These opposing sides maybe coupled to each other with conventional fasteners (e.g., bolts,rivets, welds, and/or adhesive). Illustratively, front arm members 56,head 62, and head tube 64 may be comprised of metallic materials, forexample an aluminum or chrome moly material. It may be appreciated thatthe uniform construction of front arm members 56, head portion 62, andhead tube 64 eliminates the need for heat treating front frame 52.

Frame rails 58 extend rearwardly from head portion 62 and define abackbone of vehicle 2. Frame rails 58 may be comprised of steel andallow front frame 52 to be adjusted for stiffness and yet aresufficiently flexible to accommodate various tolerances and forces inframe assembly 50 during assembly. More particularly, frame rails 58allow powertrain assembly 130 to be coupled to frame assembly 50 withoutpre-stressing frame assembly 50. Additionally, because of the use offrame rails 58, spacers and other adjusters may not be needed whenassembling various components of vehicle 2 with frame assembly 50. Theforward ends of frame rails 58 include front couplers 78. Front couplers78 may be cast portions welded to frame rails 58. Alternatively, frontcouplers 78 may be coupled to frame rails 58 with fasteners (e.g.,bolts, rivets). As shown best in FIG. 4, front couplers 78 may partiallyextend into frame rails 58 when coupled thereto.

Frame rails 58 also may include plates 80 extending downwardlytherefrom. Plates 80 may increase the strength and stiffness of frontframe 52. Illustratively, as shown in FIG. 4, plates 80 extend outwardlyfrom frame rails 58. Plates 80 include a post 86 and isolators 88 (FIG.5), as further detailed herein. Plates 80 are coupled to a portion offrame rails 58 and a portion of front couplers 78. For example, plates80 may be integrally coupled to frame rails 58 and front couplers 78through welding. Alternatively, plates 80 may be coupled to frame rails58 and front couplers 78 with mechanical fasteners (e.g., bolts,rivets).

Referring to FIGS. 3 and 4, frame rails 58 are coupled to head portion62 with fasteners 74, 76. More particularly, front couplers 78 arepositioned within recesses 71 of head portion 62 such that frontcouplers 78 are generally flush with head portion 62. Fasteners 74extend through apertures 79 of front couplers 78 and apertures 72 ofhead portion 62. Illustratively, fasteners 74 enter head portion 62 on aleft side of vehicle 2 and extend fully through head portion 62 tocouple with fasteners 76 on a right side of vehicle 2. In oneembodiment, dowels or spacers 90 may be positioned within apertures 79of couplers 78 to accommodate varying tolerances in front frame 52.Alternatively, front frame 52 may not include dowels 90. Plates 80 alsoare coupled to head portion 62 when fasteners 82 are received throughapertures 83 in plates 80 and apertures 84 in head portion 62. As shownin FIGS. 3 and 4, fasteners 82 are positioned below fasteners 74, 76.The configuration and coupling of frame rails 58 and plates 80 with headportion 62 eliminates the need for heating treating front frame 52.

The rearward ends of frame rails 58 may illustratively include rearcouplers 92, which may be cast portions welded to frame rails 58.Alternatively, rear couplers 92 may be coupled to frame rails 58 withfasteners, such as bolts or rivets. As shown in FIGS. 3 and 5, rearcouplers 92 include a planar portion 94 and an upright portion 96.Planar portion 94 extends laterally outward from upright portion 96 andis directly coupled to frame rails 58. Upright portion 96 includes aplurality of apertures 98 for coupling frame rails 58 to side members 60of mid-frame 53. More particularly, fasteners 106 are received throughapertures 100 of side members 60 and apertures 98 in order to coupleside members 60 to frame rails 58.

Upright portion 96 further includes a plurality of apertures 99 forcoupling with a support assembly 116, as shown in FIG. 5. Supportassembly 116 includes a plate 118 having a plurality of apertures 119and a bracket 120 having flanges 122. Flanges 122 include apertures 124.Plate 118 is positioned above bracket 120 and fasteners 126 are receivedthrough apertures 119 of plate 118, apertures 124 of flanges 122, andapertures 99 of upright portion 96 of rear couplers 92. As such, supportassembly 116 is coupled to rear couplers 92.

Mid-frame 53 includes side members 60 extending downwardly from framerails 58. As shown in FIGS. 1-3 and 6, side members 60 also extendoutwardly from frame rails 58 of front frame 52. Side members 60 includea plurality of apertures 102, 104 for coupling with powertrain assembly130, as detailed further herein. Illustratively, side members 60 areformed through casting methods.

As shown in FIG. 3, side members 60 also includes a rear interface 108for coupling with rear frame 54. Rear frame 54 includes a frontinterface 110 that is complimentary with and coupled to rear interface108 of side members 60 with a plurality of fasteners 114. Fasteners 114extend through apertures 112 of front interface 110 of rear frame 54 andinto apertures on rear interface 108 of side members 60. Illustratively,there are four fasteners 114 for coupling rear frame 54 to side members60. As shown in FIG. 3, fasteners 114 extend a longitudinal direction(i.e., are generally parallel to the centerline).

Referring now to FIG. 6, powertrain assembly 130 is coupled to frontframe 52 of frame assembly 50. As detailed herein, powertrain assembly130 is a structural member of vehicle 2 and couples front frame 52 tomid-frame 53 along a lower portion of vehicle 2. Powertrain assembly 130includes an engine 132 and a transmission 138. In one embodiment, engine132 and transmission 138 are an integral powertrain unit.Illustratively, engine 132 is a V-twin engine having two cylindersoperably coupled to a crankcase 136. The cylinders and the correspondingcylinder heads may not include fins for cooling and, as such, engine 132may be a liquid-cooled engine fluidly coupled to cooling assembly 240,as further detailed herein. Additional details regarding engine 132 andtransmission 138 are disclosed in co-pending U.S. Provisional PatentApplication Ser. No. 61/801,033, filed on Mar. 15, 2013, the completedisclosure of which is expressly incorporated by reference herein.

A front end of crankcase 136 and a rear end of crankcase 136 are coupledto frame assembly 50, however, the cylinders are not directly coupled toframe assembly 50. Crankcase 136 includes a plurality of lugs 140 forcoupling with front frame 52 and mid-frame 53. In one embodiment, onlycrankcase 136 is directly coupled to front frame 52 and mid-frame 53. Inthis way, crankcase 136 may take up the loads in the bottom portion offront frame 52 and mid-frame 53. Additionally, frame rails 58 may beused to take up the loads in the top portion of front frame 52.

The front end of crankcase 136 includes lugs 140 that couple with thelower ends of front arm members 56. As shown in FIG. 6, fasteners 142extend through apertures 70 in front arm members 56 and lugs 140 tosupport the front end of powertrain assembly 130 on front frame 52.Fasteners 142 also may extend through a spacer 144 and/or a locatingdowel 146. Spacer 144 may be used to position powertrain assembly 130 onfront frame 52. For example, as shown in FIG. 6, spacer 144 is coupledto the inner surface of front arm member 56 on the right side of vehicle2. However, front arm member 56 on the left side of vehicle 2 may notinclude spacer 144. As such, powertrain assembly 130 may be shifted tothe left within front frame 52 by spacer 144. Locating dowel 146 may bepositioned within apertures 70 in order to accommodate varyingtolerances between fasteners 142 and front arm members 56.

The rear end of crankcase 136 is coupled to mid-frame 53 through sidemembers 60. In this way, crankcase 136 is a structural component ofvehicle 2 and couples together the lower portions of front frame 52 andmid-frame 53. As shown in FIG. 6, fasteners 148 are received throughapertures 102 and 104 of side members 60. Fasteners 148 extend throughspacers 144 and into lugs 140 of crankcase 136. Illustratively, spacers144 are positioned on a right side of crankcase 136 such that powertrainassembly 130 is shifted to the left in frame assembly 50. Fasteners alsomay extend through locating dowels 146, which may be positioned withinapertures 102 and 104 of side members 60. Locating dowels 146 mayaccommodate varying tolerances between fasteners 142 and side members60. Fasteners 149 couple with fasteners 148 to secure the rear end ofcrankcase 136 to side members 60.

Frame rails 58 are positioned above powertrain assembly 130 and may beremoved from front frame 52 and mid-frame 53 in order to assemble andservice powertrain assembly 130. For example, spark plugs may extendfrom the center of the heads of the cylinders or may be positioned at anangle on the heads of the cylinders. As such, by removing frame rails58, spark plugs and other components of powertrain assembly 130 (e.g.,cylinders 74) may be repaired or replaced without the need to uncouplepowertrain assembly 130 from frame assembly 50. In other words,powertrain assembly 50 does not need to be “dropped out” of frameassembly 50 for repairs or maintenance. Additionally, due to the ease ofaccessing portions of powertrain assembly 130, powertrain assembly 130may be positioned low on frame assembly 50, thereby lowering the centerof gravity of vehicle 2. It may be appreciated that fuel tank 330 andseat 28 are removed in order to access powertrain assembly 130.Additionally, at least one frame rails 58 may be removed in order tofacilitate access to powertrain assembly 130.

As shown in FIGS. 6 and 7, two-wheeled vehicle 2 may include a sidestand assembly 150 coupled to crankcase 136 and/or side members 60. Inone embodiment, side stand assembly 150 is coupled to crankcase 136and/or side members 60 in three locations. Illustratively, side standassembly 150 includes a base member 152, a lever arm 154, and a footmember 156. Base member 152 is coupled to lever arm 154 with a pivot pin157 and is coupled to crankcase 136 with fasteners 158. Moreparticularly, fastener 158 extends through an aperture 105 of sidemember 60 of mid-frame 53 in order to couple side stand assembly 150with frame assembly 50. Additionally, side stand assembly 150 may becoupled to side member 60 with fastener 148 extending through aperture104 of side member 60. Alternatively, side stand assembly 150 may becoupled to a fastener 159 extending from crankcase 136 of powertrainassembly 130. In a further embodiment, side stand assembly 150 may beadjacent the front end of crankcase 136 to further increase thestability of vehicle 2.

In operation, lever arm 154 may be rotated about pivot pin 157 toposition foot member 156 against a ground surface. In this way, vehicle2 is supported on the ground surface with side stand assembly 150. Whenvehicle 2 is operating, lever arm 154 may be pivoted about pivot pin 157to the position shown in FIG. 7, such that side stand assembly 150 doesnot interfere with the ground surface.

In one embodiment, side stand assembly 150 includes a sensor member 166.Sensor member 166 may send a signal to the electrical system of vehicle2 (e.g., the engine control unit (“ECU”) or the vehicle control unit(“VCU”)) to indicate that vehicle 2 is not operational and/or is leaningon side stand assembly 150. As such, the ECU and/or VCU may signal othercomponents of vehicle 2 when side stand assembly 150 is engaged.

Referring now to FIGS. 8 and 9, a rear end of side members 60 supportsthe rear end of powertrain assembly 130. As shown, an anti-lock brakemodule 160 of brake assembly 12, a purge valve 162 operably coupled tofuel tank 300, an evaporator canister 164 operably coupled to fuel tank300, and a voltage regulator 168 of the electrical system are supportedat the rear end of side members 60. Purge valve 162 and evaporationcanister 164 are provided for eliminating air and water from fuel lines.It may be appreciated that anti-lock brake system module 160, purgevalve 162, evaporation canister 164, and voltage regulator 168 arepositioned below a swing arm 382 of rear suspension assembly 380.

As shown in FIGS. 8 and 9, a support plate 170 includes a first opening172 having a cantilevered arm 173 extending therein. Support plate 170also includes a second opening 174, which is positioned forward of, andis larger than, first opening 172. First and second openings 172, 174may be included for cooling anti-lock brake system module 160, purgevalve 162, evaporation canister 164, and/or voltage regulator 168.Support plate 170 also includes an upper tab 178 for coupling toanti-lock brake module 160 with a fastener 202, and a plurality of lowertabs 176 for coupling to a support base 180 with fasteners 196.

Support base 180 includes an opening 182. Upstanding tabs 188 extendupwardly from opposing sides of opening 182. Lower tabs 176 of supportplate 170 align with upstanding tabs 188 of support base 180 and arecoupled thereto with fasteners 196 and 194. Illustratively, fasteners196 are bolts and fasteners 194 are weld nuts. Alternative embodimentsof fasteners 194, 196 may be used to couple support plate 170 to supportbase 180.

Additionally, support base 180 includes forward arms 186 and rearwardarms 184. Forward arms 186 couple support base 180 to side members 60with fasteners 190. More particularly, fasteners 190 extend throughapertures 107 in side members 60 and couple with inner fasteners,illustratively weld nuts 192, on forward arms 186. Similarly, fasteners208 couple rearward arms 184 of support base 180 to side members 60. Asshown in FIG. 9, the rear ends of side members 60 includes tabs 204having apertures 206. Fasteners 208 extend through apertures 206 in tabs204 and couple with fasteners, illustratively weld nuts 192, on rearwardarms 184.

Both support plate 170 and support base 180 are positioned between sidemembers 60 such that anti-lock brake system module 160, purge valve 162,evaporation canister 164, and voltage regulator 168 also are generallysupported between side members 60. In one embodiment, voltage regulator168 is coupled to an underside of support base 180 and extends belowside members 60. In this way, voltage regulator 168 is positioned belowswing arm 382 of rear suspension assembly 380 in order for cooling airto flow across voltage regulator 168. Similarly, evaporation canister164 may be coupled to the underside of support plate 170 with fasteners198 and 200 and also extends below side members 60. As shown,evaporation canister 164 may include brackets 165 for coupling tosupport plate 170.

Purge valve 162 and anti-lock brake system module 160 may be supportedabove support plate 170 and support base 180. For example, purge valve162 may include a slot 163 which receives cantilevered arm 173 ofsupport plate 170. In this way, purge valve 162 may slide ontocantilevered arm 173 within first opening 172 of support plate 170.Additionally, anti-lock brake system module 160 is coupled to upper tab178 with fastener 202 and is generally positioned above second opening174.

Referring to FIGS. 10 and 11, an upper portion of side members 60 ofmid-frame 53 supports a casing 210 for at least one battery and othercomponents of the electrical system, such as a control module, asolenoids, and fuses. Additionally, casing 210 may support a coolantbottle 230. Seat 28 (FIG. 24) may be positioned above casing 210 andcoolant bottle 230. Coolant bottom 230 is positioned adjacent powertrainassembly 130 and, as such, is exposed to the heat generated bypowertrain assembly 130. Therefore, coolant bottle 230 is comprised of amaterial configured to withstand the heat of powertrain assembly 130. Inone embodiment, coolant bottle 230 is comprised of a nylon filledmaterial.

Coolant bottle 230 also is opaque and may be black in color. In thisway, various electrical components supported by casing 210 areconcealed, thereby increasing the aesthetics of vehicle 2. However,because coolant bottle 230 is opaque, the fluid within coolant bottle230 may not be visible. As such, coolant bottle 230 includes clear sightlines 234 which allow the operator to see the level of fluid withincoolant bottle 230. Alternatively, the front surface of coolant bottle230 may be opaque and the rear surface may be clear to allow an operatorto see the fluid therein. Additionally, coolant bottle 230 includesnipples 236, 238 which are configured to receive coolant lines in orderto flow coolant fluid from coolant bottle 230. The coolant lines (notshown) may be clear. Additionally, illustrative coolant bottle 230includes a cap 231, however, alternative embodiments of coolant bottle230 may include a plug. The plug may be configured to receive a funnelto facilitate the flow of additional coolant poured into coolant bottle230.

As shown best in FIG. 11, a plate 226 may be coupled to the rear side ofcoolant bottle 230 to support coolant bottle 230 on casing 210. Moreparticularly, plate 226 may include apertures 228 that align withapertures 224 on casing 210 and receive fasteners 225 (FIG. 10)therethrough.

Casing 210 faces away from powertrain assembly 130 and includes sidewalls 211 having a plurality of openings 212, a front wall 213, and abottom wall 214. Fasteners 222 may be received through apertures 218 ofside wall 211 and apertures 220 of side member 60 in order to couplecasing 210 to mid-frame 53. At least one battery may be positionedwithin casing 210 and, more particularly, the battery may be supportedby bottom wall 214 and secured by a lip 216 extending upwardly frombottom wall 214. Additionally, the battery may be positioned betweenside walls 211 and rearward of front wall 213. Openings 212 in sidewalls 211 allow any heat generated by the battery to escape from casing210. Other components of the electrical system of vehicle 2 may besupported on the outer surfaces of side walls 211 and bottom wall 214.

Referring now to FIGS. 12-15, cooling assembly 240 includes a radiator242, a fan 244 positioned rearward of radiator 242, and a shroud 246positioned at the lower end of radiator 242. In one embodiment, coolingassembly 240 includes a pump operably coupled to powertrain assembly 130in order to liquid cool engine 132. Additional details of coolingassembly 240 are disclosed in co-pending U.S. Provisional PatentApplication Ser. No. 61/801,033, filed on Mar. 15, 2013, the completedisclosure of which is expressly incorporated by reference herein.

Illustrative radiator 242 includes a plurality of vertical fins 243.Cooling assembly 240 is supported on front arm members 56 of front frame52. More particularly, cooling assembly 240 is supported within pocket66 of front frame 52 such that head portion 62 and front arm members 56generally surround cooling assembly 240. Cooling assembly 240 is forwardof powertrain assembly 130 and is adjacent engine 132. By positioningcooling assembly 140 close to powertrain assembly 130, the wheel base ofvehicle 2 may be decreased.

As shown in FIGS. 12 and 13, shroud 246 surrounds the lower end ofradiator 242 and is positioned below fan 244. Shroud 246 may improve airflow into cooling assembly 240. Shroud 246 is coupled to front armmembers 56 with fasteners 252. More particularly, fasteners 252 extendthrough apertures 248 in shroud 246 and apertures 254 in the lower endsof front arm members 56. Fasteners 252 couple with fasteners 250 alongan inner surface of shroud 246.

The lower end of radiator 242 is coupled to the lower end of front armmembers 56 with fasteners 256. As shown in FIG. 13, apertures 262 offront arm members 56 align with apertures 266 in tabs 268 on radiator242. As such, fasteners 256 may extend through sleeves 258, bushings 260and 264, and apertures 262 and 266 in order to couple with a fastener270 (e.g., a weld nut) and secure cooling assembly 240 to front frame52. Bushings 260 and 264 may be comprised of a polymeric material, forexample rubber, for isolating cooling assembly 240 from vibrations.

As shown in FIGS. 14 and 15, the upper end of cooling assembly 240includes a frame structure 272 coupled to shroud 246. Illustratively,frame structure 272 may be integrally coupled to shroud 246. Coolingassembly 240 also includes brackets 276 for coupling frame structure 272to front frame 52. Brackets 276 may be comprised of a polymericmaterial, for example rubber, and may isolate cooling assembly 240 fromvibrations. Brackets 276 may be coupled to head portion 62 and/or frontarm members 56 of front frame 52. As shown in FIG. 14, frame structure246 includes projections 274 which are received within apertures 278 ofbracket 276. When projections 274 extend into apertures 278, a portionof frame structure 272 is received within recesses 277 of bracket 276.Brackets 276 also include apertures 282 for receiving posts 280extending laterally from radiator 242. In this way, brackets 276 arecoupled to both radiator 242 and frame structure 272 in order to couplecooling assembly 240 to front frame 52.

It may be appreciated that only the lower end of cooling assembly 240 isdirectly coupled to front frame 52. The upper end of cooling assembly240 is secured within front frame 52 with brackets 276. In this way,cooling assembly 240 may be uncoupled from front frame 52 at the lowerend thereof and configured to slide, pivot, or otherwise move in adownward and/or forward direction in order to access powertrain assembly130. For example, cooling assembly 240 may pivot about sleeves 258 tomove radiator 242 away from powertrain assembly 130. In anotherembodiment, cooling assembly 240 may slide in a downward direction alongfront arm members 56 in order to move radiator 242 away from powertrainassembly 130. As such, cooling assembly 240 is easily removed fromvehicle 2 in order to access powertrain assembly 130 for repairs andmaintenance without the need to uncouple powertrain assembly 130 fromframe assembly 50.

Referring to FIGS. 16-19, air intake assembly 300 includes an airbox 302and an accumulator space 324. Additionally, in one embodiment, the airflowing through air intake assembly 300 may be pressurized by a pressuredevice. Air intake assembly 300 is positioned below fuel tank 330 and issupported on frame rails 58 of front frame 52, as detailed furtherherein. A portion of airbox 302 extends above frame rails 58 of frontframe 52 and a portion of airbox 302 extends below frame rails 58 tocouple with a throttle body 321. Air intake assembly also is positionedrearward of head portion 62 of front frame 52.

Illustratively, airbox 302 includes a filter 304, a tray 306, and a base308. Tray 306 rests atop an inset surface 319 of base 308. Filter 304 ispositioned above tray 306. Filter 304 is coupled to base 308 withfasteners 316 that are received within apertures 318 of base 308. Asshown in FIGS. 18 and 19, tray 306 is angled downwardly into base 308such that air entering tray 306 is directed toward accumulator space324. Accumulator space 324 is defined within head portion 62 of frontframe 52. Illustratively, accumulator space 324 is positioned rearwardof head tube 64. An opening 325 in head portion 62 engages a seal 314 onan accumulator outlet 310 of base 308. Accumulator space 324 increasesthe size of airbox 302 by forming an additional or secondary air volumefor the air entering airbox 302.

Base 308 is sealingly coupled to head portion 62 of front frame 52 withseal 314 and a clamp 312. Additionally, base 308 includes a throttlebody outlet 328 which is sealingly coupled to throttle body 321 with aseal 320. Throttle body 321 includes outlet ports 322 and may alsoinclude an electronic throttle control (“ETC”) actuator 323 operablycoupled thereto. Outlet ports 322 extend below airbox 302 and belowframe rails 58 in order to provide air to the two cylinders of engine132.

The side surfaces of base 308 include recesses 327 for receivingisolators 326. Isolators 326 may be comprised of a polymeric material,for example rubber, for isolating air intake assembly 300 fromvibration. Furthermore, isolators 326 are contoured to extend withinrecesses 327 of base 308 and to extend around frame rails 58. As such,air intake assembly 300 is positioned between frame rails 58 and issecured thereto with isolators 326. Additionally, air intake assembly300 is positioned intermediate fuel tank 330 and throttle body 321.Illustratively, air intake assembly 300 is not coupled to frame assembly50 with any fasteners but rather is frictionally retained between framerails 58, fuel tank 330, and throttle body 321. To access and/or removeair intake assembly 300 from vehicle 2, one frame rail 58 may betemporarily removed from frame assembly 50 in order to remove airbox 302therefrom.

While vehicle 2 is operating, ambient air flows under fuel tank 330 andinto air intake assembly 300. More particularly, ambient air flows intofilter 304 of airbox 302, where dirt, debris, and other particulatematter is filtered from the ambient air such that the air in airbox 302is “clean” air. In one embodiment, filter 304 is comprises of asemi-porous moldable foam material that may be configured to draw airinto and through filter 304. The clean air then flows along tray 306 andinto base 308. A portion of the air in base 308 flows into throttle bodyoutlet 328, through throttle ports 322, and into engine 132.Additionally, a portion of the clean air in base 308 flows towardaccumulator outlet 310 and into accumulator space 324. The configurationand angle of tray 306 may assist with the flow of air into accumulatorspace 324. With the increased air volume in airbox 308 and accumulatorspace 324, the performance of engine 132 may be improved (e.g., theadditional air available to throttle body 321 may increase thehorsepower of powertrain assembly 130). In this way, it is possible toincrease the air available to engine 132 on a vehicle with a wheel baseless than 62 inches.

Gases from powertrain assembly 130 are exhausted from vehicle 2 throughan exhaust assembly. The exhaust assembly is a dual exhaust systemarranged along the right side of vehicle 2. Alternatively, the exhaustassembly may be a single exhaust system comprised of a single exhaustpipe.

Referring to FIGS. 20-23, fuel tank 330 is coupled to front frame 52and, illustratively, is positioned rearward of head portion 62 andforward of mid-frame 53. Fuel tank 330 is positioned above air intakeassembly 300 and frame rails 58. As shown best in FIG. 20, fuel tank 330has a low profile on front frame 52 and is angled downwardly at a rearend.

As shown in FIG. 21, fuel tank 330 is coupled to a portion of bracket120 (also shown in FIG. 5). More particularly, a support plate 332 iscoupled to the bottom surface of fuel tank 330 at the rear end. In oneembodiment, support plate 332 may be comprised of a rigid polymericmaterial. A bracket 334 includes a lip 335 and a plurality of apertures336. Fasteners 348 couple bracket 334 to support plate 332 at the rearend of fuel tank 330. Additionally, a coupling member 338 includes ahooking member 339 and a plurality of apertures 340. Apertures 340 ofcoupling member 338 align with apertures 342 of bracket 120 in order toreceive bushings 344 and fasteners 346 therethrough. Fasteners 346 alsoextend through a portion of bracket 334 in order to secure couplingmember 338 and bracket 120 to support plate 332 of fuel tank 330.Additionally, hooking member 339 couples with lip 335 of bracket 334 tofurther retain coupling member 338 to bracket 334. Illustratively,coupling member 338 is positioned below bracket 334 when assembledtogether. In this way, fuel tank 330 is coupled to front frame 52through bracket 120 and is positioned forward of plate 118 (FIG. 20).Bracket 334 and/or coupling member 338 may be comprised of a polymericmaterial for isolating fuel tank 330 from vibrations.

Additionally, the front end of fuel tank 330 mounts to head portion 62of front frame 52. More particularly, the underside of fuel tank 330, asshown in FIG. 21, includes a coupler 349 for receiving isolators 88 andposts 86 (FIG. 5) on head portion 62. Isolators 88 are received overposts 86 and are supported on couplers 349. Because isolators 349 arecomprised of a polymeric material, isolators 349 may isolate fuel tank330 from vibrations.

A fuel pump assembly 350 is supported on support plate 332 at the rearend of fuel tank 330, as shown in FIGS. 22 and 23. Additionally, bypositioning fuel pump assembly 250 at the rear of fuel tank 330, the lowprofile of fuel tank 330 on front frame 52 may be maintained. Fuel pumpassembly 350 includes a pump 352 and pick-up filters or screens 354.Screens 354 may be coupled to pump 352 with arms 356. As such, fuel isdrawn into pump 352 through screens 354. The fuel is filtered in screens354 before flowing into pump 352.

The angled configuration of fuel tank 330 allows fuel to flow rearwardlyfrom the front end of fuel tank 330 to the rear end and towards fuelpump 352. However, in order to avoid backsplash as the fuel flowsrearwardly, backsplash panels 358 are positioned along the flow path ofthe fuel within fuel tank 330. Illustratively, backsplash panels 358 arepositioned forward of pump 352 and screens 354. As such, backsplashpanels 358 generally regulate the flow of fuel within fuel tank 330.Additionally, if vehicle 2 is leaning in a forward direction duringoperation (e.g., vehicle 2 is positioned downhill), backsplash panels358 prevent the fuel at the rear end of fuel tank 330 from rapidlyflowing forward toward the front end of fuel tank 330. Withoutbacksplash panels 358, fuel pump 352 may be starved of fuel when vehicle2 is moving downhill.

As shown in FIG. 24, seat 28 includes a first seat portion 28 a and asecond seat portion 28 b. First and second seat portions 28 a, 28 b maybe integrally coupled together. Alternatively, first and second seatportions 28 a, 28 b may be separated from each other. First seat portion28 a defines a seat bottom for the operator of vehicle 2. Second seatportion 28 b may be configured as a passenger seat bottom or as a backrest portion for the operator. In one embodiment of vehicle 2, secondseat portion 28 b may be removed such that vehicle 2 includes only firstseat portion 28 a.

A support plate 370 is positioned below first seat portion 28 a andincludes a tab 372 having an aperture 373. Aperture 373 is aligned withan aperture 366 in plate 118 and a fastener 368 extends throughapertures 373 and 366 in order to couple seat 28 with mid-frame 53. Asshown in FIG. 24, seat 28 is supported above side members 60 ofmid-frame 53 and is positioned rearward of fuel tank 330 (FIG. 20).

Second seat portion 28 b includes a support plate 373 having a latchmember 374 and a plurality of rubber bumpers 376. Rubber bumpers 376 areconfigured to isolate seat 28 from vibrations. Latch member 374 isreceived within an opening 379 of a plate 378 coupled to rear fender400. In this way, seat 28 is coupled to mid-frame 53 through plate 118and is coupled to rear fender 400 with latch member 374.

Referring now to FIGS. 25-28, rear frame 54 is shown. Rear frame 54 iscoupled to mid-frame 53 and, more particularly, to side members 60. Rearfender 400 is coupled to rear frame 54 with fasteners 402 and 404.Illustratively, four fasteners 402 and four fasteners 404 couple rearfender 400 to rear frame 54 through apertures 414 on rear fender 400 andapertures 416 on rear frame 54. The shape of rear fender 400 generallycorresponds to the shape of rear frame 54. Additionally, the location ofseat mounting plate 378 on rear frame 54 maintains the low position ofseat 28 and assist in lowering the center of gravity of vehicle 2. Rearframe 54 also may include a guard panel 394 coupled thereto withfasteners 396. Guard panel collects dirt, mud, and other debris that maybe spun off of rear wheel 10.

Rear fender 400 also includes an opening 406 for receiving a rear lightassembly 462. As shown in FIG. 28, rear light assembly 462 includes amounting panel 419 which supports a tail light 420, a right-side turnsignal 424, a left-side turn signal 426, a license plate light 422, anda rear reflector 428. Mounting panel 419 and/or tail light 420 also maysupport a wiring harness for the wires operating tail light 420, turnsignals 424 and 426, and license plate light 422. In the illustrativeembodiment of FIG. 28, tail light 420 acts as a junction box to supportthe wiring of tail light 420, turn signals 424 and 426, and licenseplate light 422. Rear fender 400 also may be configured to supportsaddlebags or other cargo devices.

Referring now to FIGS. 26 and 27, the front end of illustrative rearfender 400 may not be symmetric. Rather, a right front side 408 of rearfender 400 is longer than a left front side 410. Right front side 408 isconfigured to contact swing arm 382 and, more particularly, isconfigured to contact a recess 412 at a front cross-member 460 of swingarms 382. Left front side 410 of rear fender 400 is profiled andincludes a notch 411 therein. Recess 412 of cross-member 460 is rearwardof a pivot axle 430 of rear suspension assembly 380 and receives rightfront side 408 of rear fender 400. As such, when vehicle 2 is viewedfrom the right side, rear fender 400 appears to continuously extend intoswing arm 382.

Rear suspension assembly 380 is coupled to mid-frame 53 and extendspartially around rear fender 400. Rear suspension assembly 380 includesa pair of swing arms 382 coupled together through front cross-member460. Additionally, rear suspension assembly 380 includes a pair ofshocks 384 coupled to swing arms 382 and frame assembly 50. Moreparticularly, and as shown in FIG. 26A, an upper end of shocks 384 iscoupled to aperture 392 of side members 60 of mid-frame 53 withfasteners 288. Additionally, a lower end of shocks 384 is coupled toapertures 387 on swing arms 382. As shown in FIG. 25, shocks 384 areangled relative to swing arms 384 to give the appearance of a “hardtail,” however, shocks 384 are configured to accommodate the suspensionload even at this angle. Alternatively, shocks 384′ may be coupled torear frame 54, as shown in FIG. 26B. In one embodiment, a bracket 385may be used to support shocks 384′ on the front end of rear frame 54. Assuch, the angle of shocks 384′, relative to swing arms 382, may begreater than the angle of shocks 384 of FIG. 26A, relative to swing arms382.

As with shocks 384, swing arms 382 also couple to side members 60 ofmid-frame 53. More particularly, the front end of swing arms 382 coupleto apertures 391 (FIG. 1) of side members 60. A pivot axle 430 extendsbetween side members 60 and receives a fastener 390 therein. As shown inFIGS. 29-31, the front end of swing arms 382 includes apertures 387 forcoupling with pivot axle 430. Additionally, fastener 390, flangedspacers 432, a first washer 434, a clip 436, a first bearing 438, asecond bearing 440, a first seal 42, a third bearing 444, a second seal446, a second washer 448, and a fastener 449 are used to support pivotaxle on swing arms 382. As shown in FIG. 30, pivot axle 430 includes athreaded end 450 having an internally profiled surface 452. Acylindrical aperture 454 of pivot axle 430 extends between the outerends of pivot axle 430.

As shown in FIG. 30, internally profiled surface 452 of pivot axle 430may be engaged with a tool, for example a wrench, to adjust the spacingbetween side members 60 when swing arms 382 are coupled thereto. Moreparticularly, the spacing between swing arms 382 is fixed because frontcross-member 460 defines the distance therebetween. However, due to theflexibility of frame rails 58, side members 60 may be moved inwardly oroutwardly to accommodate the position of swing arms 382. In other words,side members 60 are configured to take up the tolerance between sidemembers 60 and swing arms 382. In operation, as shown in FIG. 29,aperture 391 of side member 60 on the right side of vehicle 2 includesinternal threads for engaging with threaded end 450 of pivot axle 430.As such, pivot axle 430 threadedly engages with aperture 391. A tool maybe positioned against internally profiled surface 452 to rotate pivotaxle 430 further from aperture 391 or to rotate pivot axle 430 outwardlywithin aperture 391. In this way, the distance between side members 60accommodates the size and position of swing arms 382.

With the pivot axle 430 in the proper position, fastener 390 may beinserted through cylindrical aperture 454 of pivot axle 430 to coupleswing arms 382 to side members 60. As shown in FIG. 31, aperture 387 ofthe left side swing arm 382 may include washer 434, clip 436, first andsecond bearings 438, 440, and flanged spacer 432. Illustratively, firstand second bearings 438, 440 are ball bearings. Fastener 390 extendsthrough aperture 387 on the left side swing arm 382 and throughapertures in washer 434, clip 436, first and second bearings 438, 440,and flanged spacer 432 in order to extend through cylindrical aperture454 of pivot axle 430. Fastener 390 also extends through aperture 387 onthe right side swing arm 382 and through apertures of flanged spacer432, seal 442, bearing 444, seal 446, washer 448, and is coupled tofastener 449. Illustratively, bearing 444 is a needle bearing andfastener 449 is a nut. In this way, swing arms 382 are coupled to sidemembers 60.

Swing arms 382 are configured to pivot about pivot axle 430 duringoperation of vehicle 2. Additionally, the arrangement of fastener 390,flanged spacers 432, first washer 434, clip 436, first bearing 438,second bearing 440, first seal 42, third bearing 444, second seal 446,second washer 448, and fastener 449 forms a “float” side on the rightside swing arm 382 and a “fixed” side on the left side swing arm 382.More particularly, because bearing 444 is a needle bearing, some limitedmovement is allowed within aperture 387 and, as such, defines the“float” side. Conversely, bearings 438, 440 are single-row ball bearingswhich are fixed within aperture 387 and, as such, define the “fixed”side. Under low torque, pivot axle 430 contacts side member 60 on theleft side of vehicle 2 because pivot axle 430 is configured to slide tothe left along bearing 444.

Referring to FIG. 32, a passenger foot peg assembly 456 includes a footmember 457 and a cover member 458. Foot member 457 is coupled to covermember 458, which is positioned over fastener 390 for swing arms 382.More particularly, fasteners 459 are coupled to apertures 455 on swingarm 382 in order to couple cover member 458 and foot member 457 thereto.

As shown in FIG. 33, vehicle 2 includes a belt drive assembly operablycoupled to powertrain assembly 130. The belt drive assembly includes adriven wheel 476 and a belt 478. Belt 478 is driven by powertrainassembly 130 and drives wheel 476 in order to rotate a rear axle 480 andrear wheel 10 when operating vehicle 2. As shown in FIG. 33, belt 478may be sufficiently narrow to fit within a rim of wheel 476.Illustratively, wheel 476 is positioned inward of left side swing arm382.

As shown in FIGS. 33 and 34, a rear axle adjustment member 470 isincluded on rear axle 480 and couples rear axle 480 with swing arms 382.More particularly, a head 471 of adjustment member 470 is positionedwithin a rear end of swing arms 382 and a post 472 is coupled to head471. Post 472 extends through a rear aperture 479 of swing arms 382 andis secured on swing arms 382 with a fastener 477.

An outer end of rear axle 480 extends through an opening in head 471 andis partially outward of swing arm 382. A slotted plate 473 having aplurality of slots 482 is received over rear axle 480 and theappropriate slot 482 is aligned with a slot 484 on swing arm 382. Thisposition of slotted plate 473 is maintained with a nut 474 and a pin 475that extends through an aperture 486 of rear axle 480. The same slot 482on the opposing slotted plate 473 on opposing swing arm 382 is alignedwith slot 484 on swing arm 382 in order to secure rear axle 480 and rearwheel 10 in proper alignment on swing arms 382.

Referring to FIGS. 35 and 36, front end 4 of vehicle 2 includes steeringassembly 24, controls 26, and handlebars 30. Handlebars 30 may bemounted on triple clamp assembly 32 with brackets 500, which may becoupled to an operator gauge 502. In this way, a portion of operatorgauge 502 may cooperate with triple clamp assembly 32 to mounthandlebars 30. Fasteners 504 extend through apertures in brackets 500and into apertures in support members 506 on an upper portion 36 oftriple clamp assembly 32. As such, handlebars 30 are supported onvehicle 2 through triple clamp assembly 32. Upper portion 36 of tripleclamp assembly 32 is coupled to head portion 62 with a fastener 35 andis coupled to fork members 34 with fasteners 38. Triple clamp assembly32 also includes a lower member 37 coupled around forks 24 withapertures 39.

Operator gauge 502 is angled rearwardly toward an operator in seat 28and may act as a shroud. As such, an additional shroud or cover is notrequired at front end 4 of vehicle 2. In one embodiment operator gauge502 is mounted rearwardly of the axis for handlebars 30.

Alternatively, as shown in FIG. 37, handlebars 30′ may be coupled toupper portion 36′ of triple clamp assembly 32′ with brackets 500′ andsupport members 506′ However, operator gauge 502′ may be positionedforward of the axis of handlebars 30′. In this way, triple clampassembly 32′ may mount handlebars 30′ to vehicle 2, however, operatorgauge 502′ is not integrally supported with handlebars 30′.

Handlebars 30 include mirrors 514 and levers 516. Levers 516 may bethrottle and/or brake levers for operating vehicle 2. Additionally,handlebars 30 may include additional operator controls 26. For example,electronic functionality for various aspects, accessories, andcomponents of vehicle 2 may be activated by depressing a buttonconnected to a momentary switch on handlebars 30. In one embodiment, thebutton is depressed for a predetermined length of time in order toactivate the electronic functionality. The ECU is configured to detectthe signal outputted by the momentary switch and activate theappropriate functionality. Specific patterns for moving the button wouldbe recognized by ECU through different output signals. In oneembodiment, a short push or tap on the button would provide one signalto the ECU, while a depression for a predetermined length of time wouldoutput another signal to ECU. The various signals to the ECU trigger theECU to activate various functionalities of vehicle 2.

Front end 4 of vehicle 2 may also include a headlight 510 and turnsignals 508. The wiring for headlight 510 and turn signals 508 may becoupled within a cover or bucket 512 of headlight 510.

While this invention has been described as having an exemplary design,the present invention may be further modified within the spirit andscope of this disclosure. This application is therefore intended tocover any variations, uses, or adaptations of the invention using itsgeneral principles. Further, this application is intended to cover suchdepartures from the present disclosure as come within known or customarypractice in the art to which this invention pertains.

What is claimed is:
 1. A two-wheeled vehicle, comprising: a frameassembly including: a front frame portion including a head portion, aplurality of generally vertically-extending frame tubes, and a pluralityof generally longitudinally-extending frame tubes; a mid-frame portionremovably coupled to the front frame portion; and a rear frame portionremovably coupled to the mid-frame portion; a plurality ofground-engaging members for supporting the frame assembly; and an airintake assembly coupled to the head portion, thelongitudinally-extending frame tubes being angled outwardly to increasea distance therebetween, and the air intake assembly being positionedbetween the longitudinally-extending frame tubes and including channelmembers configured to removably receive the longitudinally-extendingframe tubes, wherein the air intake assembly is frictionally retainedbetween the longitudinally extending frame tubes.
 2. The two-wheeledvehicle of claim 1, wherein an upper portion of the air intake assemblyis positioned above the longitudinally-extending frame tubes and a lowerportion of the air intake assembly is positioned below thelongitudinally-extending frame tubes.
 3. The two-wheeled vehicle ofclaim 2, wherein the head portion defines an accumulator volume and isconfigured to received air from the air intake assembly.
 4. Thetwo-wheeled vehicle of claim 3, wherein the air intake assembly includesa filter, and air is configured to flow from the filter into the headportion of the front frame portion.
 5. The two-wheeled vehicle of claim2, further comprising a fuel tank supported by thelongitudinally-extending frame tubes.
 6. The two-wheeled vehicle ofclaim 5, wherein the fuel tank is positioned above the air intakeassembly.
 7. The two-wheeled vehicle of claim 6, further comprising athrottle body, and the air intake assembly is supported on the throttlebody.
 8. The two-wheeled vehicle of claim 7, wherein the air intakeassembly is further frictionally retained between the fuel tank, and thethrottle body.
 9. The two-wheeled vehicle of claim 1, wherein thelongitudinally-extending frame tubes are comprised of steel.
 10. Thetwo-wheeled vehicle of claim 1, wherein the front and rear frameportions are cast.
 11. The two-wheeled vehicle of claim 1, wherein thechannel members are positioned on each lateral side of the air intakeassembly and have a shape complementary to a shape of thelongitudinally-extending frame members.
 12. The two-wheeled vehicle ofclaim 11, wherein the channel members are U-shaped.
 13. A two-wheeledvehicle, comprising: a frame assembly including: a front frame portionincluding a head portion, a plurality of generally vertically extendingframe tubes, and a plurality of generally longitudinally-extending frametubes; a mid-frame portion removably coupled to the front frame portion;and a rear frame portion removably coupled to the mid-frame portion; aplurality of ground-engaging members for supporting the frame assembly;an air intake assembly coupled to the head portion and including afilter, a first portion of air received into the air intake assembly isdirected from the filter of the air intake assembly into the headportion of the front frame portion; and a throttle body coupled to theair intake assembly, a second portion of the air received into the airintake assembly flow directly from the filter into the throttle body.14. The two-wheeled vehicle of claim 13, further comprising a fuel tank,and the air intake assembly is frictionally retained between thelongitudinally-extending frame tubes, the fuel tank, and the throttlebody.
 15. The two-wheeled vehicle of claim 13, wherein the filter is asemi-porous moldable foam.
 16. The two-wheeled vehicle of claim 13,wherein the air intake assembly further includes a tray positioned belowthe filter, and the tray is angled downwardly to direct air from thefilter to an accumulator volume defined by the head portion of the frontframe portion.
 17. A two-wheeled vehicle, comprising: a frame assemblyincluding: a front frame portion including a head portion, a pluralityof generally vertically-extending frame tubes, and a plurality ofgenerally longitudinally-extending frame tubes, wherein the head portiondefines an accumulator volume and is configured to received air from anair intake assembly; a mid-frame portion removably coupled to the frontframe portion; and a rear frame portion removably coupled to themid-frame portion; a plurality of ground-engaging members for supportingthe frame assembly; and the air intake assembly coupled to the headportion and the longitudinally-extending frame tubes, thelongitudinally-extending frame tubes being angled outwardly to increasea distance therebetween, and the air intake assembly being positionedbetween the longitudinally-extending frame tubes and including channelmembers configured to receive the longitudinally-extending frame tubes.18. The two-wheeled vehicle of claim 17, wherein an upper portion of theair intake assembly is positioned above the longitudinally-extendingframe tubes and a lower portion of the air intake assembly is positionedbelow the longitudinally-extending frame tubes.
 19. The two-wheeledvehicle of claim 17, wherein the air intake assembly includes a filter,and air is configured to flow from the filter into the head portion ofthe front frame portion.
 20. The two-wheeled vehicle of claim 17,further comprising: a fuel tank supported by thelongitudinally-extending frame tubes; and a throttle body, wherein theair intake assembly is supported on the throttle body.
 21. Thetwo-wheeled vehicle of claim 20, wherein the air intake assembly isfrictionally retained between the longitudinally-extending frame tubes,the fuel tank, and the throttle body.
 22. The two-wheeled vehicle ofclaim 17, wherein the front and rear frame portions are cast.